PowerPoint Presentation

							                 Harjavalta industrial ecopark as an example to
               develop environmental friendliness of carbon steel
                Jyrki Heino & Tuomo Koskenkari (Eka Chemicals)


Introduction
The evolution history and present state of
Harjavalta Industrial Park
Harjavalta Industrial Park as an industrial
ecosystem
Major environmental problems and challenges of
carbon steel industry
Industrial ecology and carbon steel making
Conclusions
Criticism
The definition and the goal of Industrial Ecology


  Industrial ecology is an interdisciplinary frame-
  work for designing and operating industrial
  systems as living systems interdependent with
  natural systems.


  The main target of industrial ecology is to learn
  from nature to develop a closed-loop industrial
  symbiosis, where the synergies between various
  industries can convert waste into products or
  feedstock to balance environmental and economic
  performance within emerging understanding of
  local and global ecological constraints.
   The definition and the goal of Industrial
    Ecosystem by Lowe, Moran and Holmes

An eco-industrial park (EIP) is a community of manufacturing
and service businesses located together with surrounding
community. Member businesses seek enhanced environmental,
economic, and social performance through collaboration in
managing environmental and resource issues.



The goal of an EIP is to improve the economic performance of the
participating companies and the community while minimizing
their environmental impacts.
   The history of Harjavalta industrial area
1944 Copper factory is moved from Imatra to Harjavalta.
1945 The start up of the Outokumpu copper factory
1947 The start up of the Kemira sulfuric acid plant
The history of Harjavalta industrial area continued…


   1944 Copper factory is moved from Imatra to Harjavalta.
   1945 The start up of the Outokumpu copper factory
   1947 The start up of the Kemira sulfuric acid plant
   1949 Outokumpu copper flash smelter wents to operation
   1959 Outokumpu nickel flash smelter wents to operation
   1971 The start up of the oxygen plant
   1995 The AGA hydrogen plant start up
   1995 The direct Outokumpu nickel process (DON)
   2000 OMG Harjavalta Nickel Ltd is founded
   2000 Porin Lämpövoima Ltd starts the energy production
   2002 OMG starts the nickel chemical production
   2004 New Boliden Harjavalta Copper Ltd is founded
  The utilisation chain of sulphur starting from a copper
  quarry to sulphur dioxide, sulphuric acid and ending up
   at consumer’s dinner-table (Koskenkari & Heino 2001)

Raw material                                       Copper deposit
acquisition

Raw materials                                      Copper flash
refining                                           smelting off gases

Transporting


Products making                                      Surphurric acid
                                                     plant
Sulphure chemicals      Ilmenite         Bauxite                          Apatite       Potassium
using / Raw material    deposit          deposit                          mine          mine                           Natural gas
acquisition

 Raw materials          Ilmenite         Bauxite      Sulphuric         Phosphorous     Potassium         Nitric                        Sulphur
                                                                                                                        Ammonia
 refining                                             acid              acid            chloride          acid                          dioxide

Transporting
                                                                                                                                       ClO2 -
                        TiO2-                                                                                                          making
 Products making        plant           FeSO4         Al2(SO4)3                     Fertilizer industry


Products using            TiO2                        Wastewater                      Barley growing                                 Chemical pulp
                                                      treatment     .                                                                (bleaching)
Transporting

                                                                                       Food                        Sugar- and           Paper
                                                                       Cattle
Products using         Paint industry                                                  production                  starch industry      industry
                                                                       feed


                                                   Domestic market / Consumer
Material and energy change of
 Harjavalta Industrial Park
 (Heino & Koskenkari 2004)


 ADVANTAGES:
 Environmental and recycling
 benefits
 Better energy efficiency
 Better product diversity
 Marketing and logistic benefits
 Improved safety activity
 Imago factors
 Cultural differences is a positive
 factor in co-operation
THE MOST DANGEROUS
PLACES IN FINLAND
BECAUSE OF THE
INDUSTRIAL ACTIVITY


IN HARJAVALTA INDUSTRIAL
AREA IS MANUFACTURED OR
STORED:

Sulfur dioxide, sulfur
trioxide and sulfuric acid

Hydrogen, oxygen and petrol

Ammonia and hydrogen sulfide

Molten copper, nickel and slags
MAIN FUTURE CHALLENGES AND PLANS
 OF HARJAVALTA INDUSTRIAL PARK

• UTILISATION OF COPPER SLAG

• BETTER UTILISATION OF
  GRANULATED NICKEL SLAGS

• LOW TEMPERATURE HEAT ENERGY
  UTILISATION IN GREEN HOUSE PARK
  OR SOMEHWHERE ELSE IN THE
  SURROUNDING COMMUNITY
The ideas found in Harjavalta industrial ecosystem
consideration will be applied to carbon steel making by
utilizing the idea of Yukawa (Wilson 2001):

”Suppose there is something which a person
cannot understand. He happens to notice the
similarity of this something other thing which
he understands quite well. By comparing them
he may come to understand the thing which he
could not understand up to that moment. If his
understanding turns out to be appropriate, it
can be said that his thinking was really
creative.”
Different routes to manufacture carbon steel




                                 Ore based
                                 steel making
Different routes to manufacture carbon steel




                                 Scrap based
                                 steel making
Different routes to manufacture carbon steel




                                  Direct reduction
                                  based steel
                                  making
Major environmental problems and
challenges of carbon steel industry

• Steel industry is very important emitter of
  CO2. With each ton of steel based on iron ore
  approximately 2 tons of CO2 are generated
  and each ton of steel based on scrap equals
  between 0.4 and 0.8 tons. (Christmas 2000)

• There is ahead a mega jump in technological
  and economic efficiency by totally
  eliminating waste streams and fully
  exploiting synergies with other related
  industrial technologies. (Szekely 1995)
   Different ways to fullfil Szekelys (1995) ideas

• Efficient use of own iron residues (dusts, scales and sludge)
• Efficient use of secondary raw materials from other
  industries (Scrap, slags, roasting residues, plastics and
  heavy oil, etc.)
• More efficient use of slags in cement industry, in road
  construction, agriculture, as a raw material of geopolymers
  (Cheng & Chiu 2003), etc.
• Better energy efficiency with the aid of energy integration
  included pinch technology, etc. (Linblad et al. 2004)
• Low heat energy utilization in district heating, in
  greenhouses or somewhere else in the surrounding
  community.
• Coke oven gas can also be converted into H2, which can be
  fed into fuel cell battery for automobile or chemical
  industry (Emi 2004).
• Etc., etc., etc.
• Only lack of creativity or barriers of creativity will set the
  boundary conditions
The idea of Industrial
  ecology applied to
 carbon steel making
(Heino & Virtanen 2004)



Basic principle: “The primary
 production chain of the ore
  based steel making is not
disturbed (OPTIDUST 2002)”
                CONCLUSIONS I


• The ideas found in Harjavalta industrial ecosystem
  consideration can be applied to carbon steel
  making to add product efficiency, improve energy
  utilization and start new business, when different
  independent units or firms can concentrate to their
  own core know-how areas
               CONCLUSIONS II

• The use of other secondary iron raw materials
  except scrap saves natural resources, but the
  potential effect on carbon dioxide emissions is
  insignificant

• The major problem when using secondary iron
  raw materials will be the contamination of steel
  by tramp elements
               CONCLUSIONS III


• The experts of the metallurgical industry
  including metallurgist, geologist, etc., have a lot
  of knowledge of high temperature processing of
  different materials.

• With the aid of this expertise the energy
  contents of the materials can be utilized as well
  as the unwanted materials can be converted
  either to valuable products or to harmless form
  to be dumped in the nature if it can’t be reused.
               CONCLUSIONS IV
• By-product and energy efficiency development is
  one way to add steel’s friendliness to the
  environment.

• Steel have also very unique properties, which can be
  improved, if steel manufacturers can concentrate
  on their core know-how area.

• Today's industry is facing significant change from
  the process related environmental thinking towards
  product based environmental thinking, which is
  already seen in the EU product policy, where focus
  is on the total life cycle of the products.
                         CRITICISM
•   Industrial ecosystems can be large centers of dangerous materials
    and processes. The occupational safety and accident security
    risk prevention should be included into the metaphor of industrial
    ecology.

•   Industrial ecology tries to make the cycles of material in
    industrial systems similar to the cycles in natural ecosystems.
    There are some major differences between the technical and
    natural systems. One essential feature of the technical systems is
    a human control. It is difficult to say, is it good or bad. It depends
    on the future ethical decisions made by humankind.

•   The natural ecosystems have had plenty of time to develop and
    they also have time to adjust to the changes. If there will be in the
    future a stronger demand on the industry to generate fast profits,
    there is a risk that the costs of this kind of research and
    development will not be accepted (Makkonen 2004).
Thank you